Note: Descriptions are shown in the official language in which they were submitted.
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SECONDARY INSERTION FEATURE FOR ASSEMBLED PACKAGE
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35 U.S.C. 119
of U.S.
Provisional Application Serial No. 62/557,348 filed on 12 September 2017,
titled
"Secondary Insertion Feature for Assembled Package", the entire contents of
which is
hereby incorporated by reference in its entirety.
FIELD
[0002] The present disclosure relates generally to packaging systems, and more
specifically to a utility feature for inserting adjunct and/or essential
materials within an
assembled corrugated package.
BACKGROUND
[0003] Historically, small consumer appliances and other fully assembled
machines
(e.g., Keurig coffee makers) are manufactured in countries with reduced
manufacturing
and labor costs (such as Asia or Mexico), are packaged, and are then shipped
to the
United States or another country for distribution. Prior to shipment to final
retail
locations, sample materials or adjunct components, such as ingredients,
supplies, or
beverage pods (produced in North America) are included within the appliance
package.
[0004] Traditional appliance packaging designs require a disassembly of the
pallet load
of appliances, re-opening of the appliance's typically corrugated package,
insertion of the
sample or adjunct materials, resealing of the appliance packaging, and
reassembly of the
pallet load for further processing and delivery. This process consumes a high
degree of
both time and labor.
[0005] Further, manufacturing constraints, such as location, distribution
channels, and
existing manufacturing assemblies, often discourage (i) shipping sample
materials or
adjunct components to Asia, Mexico, or other appliance manufacturing centers
because
efficient use of a finite shelf-life of product is not always accomplished due
to inefficient
logistics, or (ii) a process with few unit operations or limited labor to
include sample
materials.
[0006] Therefore, there is a need for an efficient and economical way to add
sample
materials or adjunct components to a factory sealed primary packaging.
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SUMMARY
[0007] An exemplary embodiment of the present system and method overcomes the
above-mentioned disadvantages and meets the recognized need for such a device
by
providing an opening feature upon an exterior wall of a primary package which
provides
the utility of inserting adjunct and/or essential materials without requiring
the opening of
the primary (major or minor) flaps of the primary packaging. The exemplary
system and
method includes a hinged door on the outer surface of the primary package that
is re-
closable.
[0008] In a first aspect, the present disclosure includes a package. The
package
includes a primary packaging. The primary package includes walls that define
an interior
space configured to hold primary contents. The primary package further
includes a
primary access flap that is configured to enclose the primary contents within
the interior
space. The package further includes an opening feature defined in an outer
surface of at
least one wall of the primary packaging and configured to provide access to
the interior
space for adjunct materials. The opening feature is configured to provide
access to the
interior space for adjunct materials while the primary packaging maintains:
(i) the
primary access flap in a closed position; and (ii) a position of primary
contents held
within the interior space.
[0009] A number of feature refinements and additional features are applicable
in the
first aspect and contemplated in light of the present disclosure. These
feature refinements
and additional features may be used individually or in any combination. As
such, each of
the following features that will be discussed may be, but are not required to
be, used with
any other feature combination of the first aspect.
[0010] In an embodiment, the opening feature includes a hinged door configured
to
articulate over a secondary opening defined in the outer surface. The
packaging may
further include an internal feature defining an internal compartment within
the interior
space and connected to the secondary opening defined by the outer surface.
[0011] In another embodiment, the adjunct material may be arranged within a
secondary packaging. The internal compartment may be configured to receive the
secondary packaging. In some cases, the internal feature is configured to
define a friction
fit with an exterior of the secondary packaging.
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[0012] In another embodiment, the primary contents may be an appliance
comprising a
beverage machine. The adjunct materials may be consumables associate with an
operation of the beverage machine.
[0013] In some cases, the package may further include the primary contents.
The
primary packaging may be formed from a corrugated material.
[0014] In a second aspect the present disclosure includes a package. The
package
includes walls formed from a corrugated material and defining an interior
space. The
package further includes a primary access flap enclosing the interior space.
The package
further includes at least one wall defining a secondary opening in an outer
surface
extending into the interior space. The at least one wall further defines a
hinged door
covering the secondary opening. The interior space is arranged to receive
adjunct
materials through the secondary opening. The primary access flap, when opened,
allows
for access to adjunct materials.
[0015] A number of feature refinements and additional features are applicable
in the
second aspect and contemplated in light of the present disclosure. These
feature
refinements and additional features may be used individually or in any
combination. As
such, each of the following features that will be discussed may be, but are
not required to
be, used with any other feature combination of the second aspect.
[0016] In an embodiment, the hinged door may be defined by perforations formed
through the at least one wall. The hinged door may be configured to separate
from a
remainder of the at least one wall along the perforations. The hinged door may
define a
digit engagement feature configured for manipulation of the hinged door.
[0017] In another embodiment, the packaging comprises an internal feature
configured
to separate primary contents held within the interior space from adjunct
materials
received through the secondary opening. In some cases, the interior space may
be
configured to hold primary contents in a predetermined orientation. The
predetermined
orientation of the primary contents is maintained when adjunct materials are
received
through the secondary opening.
[0018] In another embodiment, the packing comprises a sealer configured to
seal the
hinged door about the opening.
[0019] In a third aspect the present disclosure includes a method for
assembling a
package. The method includes providing a primary package defining an interior
space,
the primary package including a primary access flap and an opening feature,
each
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connected to the interior space. The method further includes packaging primary
contents
with the primary package at a predetermined orientation by: (i) inserting the
primary
contents into the interior space through the primary access flap; and (ii)
sealing the
primary access flap. The method further includes packaging adjunct materials
with the
primary package by inserting the adjunct materials into the interior space
through the
opening feature, while maintaining the predetermined orientation of the
primary contents
within the interior space.
[0020] A number of feature refinements and additional features are applicable
in the
third aspect and contemplated in light of the present disclosure. These
feature
refinements and additional features may be used individually or in any
combination. As
such, each of the following features that will be discussed may be, but are
not required to
be, used with any other feature combination of the first aspect.
[0021] In an embodiment, the operation of providing a primary package further
includes forming the opening feature in a wall of the primary packaging
defining the
interior space by one or more of die-cutting, laser-cutting, or stamping.
.. [0022] In another embodiment, the opening feature includes a hinged door
defined by
perforations formed through a wall of the primary packing defining the
interior space. In
some cases, the operation of packaging the adjunct materials further includes
separating
the hinged door from a remainder of the wall along the perforations.
[0023] In another embodiment, the method further includes sealing the opening
feature
using tamper-resistant tape.
[0024] In addition to the exemplary aspects and embodiments described above,
further
aspects and embodiments will become apparent by reference to the drawings and
by study
of the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The disclosure will be readily understood by the following detailed
description
in conjunction with the accompanying drawings, wherein like reference numerals
designate like structural elements, and in which:
[0026] FIG. 1A depicts a perspective view of a packaging system;
[0027] FIG. 1B depicts the packaging system of FIG. 1A having enclosed primary
contents, as shown by a partial cut-away view of a primary packaging;
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[0028] FIG. 1C depicts the packaging system of FIG. 1B having enclosed adjunct
contents, as shown by a partial cut-away view of a secondary packaging
received by the
primary packaging;
[0029] FIG. 2 depicts a perspective view of an opening feature formed in the
primary
packaging;
[0030] FIG. 3 depicts a perspective view of a secondary packaging inserted
into the
primary packaging through the opening feature formed in the primary packaging;
[0031] FIG. 4 depicts a perspective assembled view of a secondary packaging
inserted
into and enclosed by the primary packaging;
[0032] FIG. 5 depicts a perspective assembled view of a secondary packaging
inserted
into and sealed by a tamper-resistant sealer within the primary packaging; and
[0033] FIG. 6 depicts a flow diagram for assembling a package.
[0034] The use of cross-hatching or shading in the accompanying figures is
generally
provided to clarify the boundaries between adjacent elements and also to
facilitate
legibility of the figures. Accordingly, neither the presence nor the absence
of cross-
hatching or shading conveys or indicates any preference or requirement for
particular
materials, material properties, element proportions, element dimensions,
commonalities
of similarly illustrated elements, or any other characteristic, attribute, or
property for any
element illustrated in the accompanying figures.
[0035] Additionally, it should be understood that the proportions and
dimensions
(either relative or absolute) of the various features and elements (and
collections and
groupings thereof) and the boundaries, separations, and positional
relationships presented
therebetween, are provided in the accompanying figures merely to facilitate an
understanding of the various embodiments described herein and, accordingly,
may not
necessarily be presented or illustrated to scale, and are not intended to
indicate any
preference or requirement for an illustrated embodiment to the exclusion of
embodiments
described with reference thereto.
DETAILED DESCRIPTION
[0036] The description that follows includes sample systems, methods, and
apparatuses
that embody various elements of the present disclosure. However, it should be
understood that the described disclosure may be practiced in a variety of
forms in addition
to those described herein.
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[0037] The present disclosure describes systems, devices, and techniques
related to
systems for accessing the interior portion of a primary package after
assembly, perhaps at
a different location than the initial assembly. This allows for the convenient
and
undisruptive insertion of secondary packages, samples, components, and the
like. This is
particularly advantageous when the secondary packages, samples, components,
and the
like are perishable items or items that have a limited shelf-life. According
to one
exemplary embodiment, the system for accessing the interior portion of a
primary
package after assembly includes a die-cut and hinged "trap door" which enables
access to
the interior of the package, is re-closable, and is die-cut into an exterior
wall of the
primary container.
[0038] Systems and methods described herein are presented in the context of
the
packaging of an appliance such as a Keurig coffee maker, or other beverage
machine,
including beverage machines for the production of alcoholic beverages, but can
be
applied to any number of manufactured articles that are manufactured and
packaged at a
remote location from the final distribution center. Additionally, the systems
and methods
may be used with any manufactured article that may be manufactured and
packaged prior
to final shipment, but that would benefit from the insertion of a perishable
item or an item
that has a lower shelf-life than the likely storage time of the manufactured
item, prior
to final shipping.
[0039] Reference will now be made to the accompanying drawings, which assist
in
illustrating various features of the present disclosure. The following
description is
presented for purposes of illustration and description. Furthermore, the
description is not
intended to limit the inventive aspects to the forms disclosed herein.
Consequently,
variations and modifications commensurate with the following teachings, and
skill and
knowledge of the relevant art, are within the scope of the present inventive
aspects.
[0040] FIG. 1A illustrates an appliance packaging system 100 (or more
generally
referred to herein as a "package"), according to one embodiment. As shown, the
appliance packaging system 100 or package may include a primary packaging 110
and a
secondary packaging 120. The illustrated primary packaging 110 is configured
to house a
manufactured article, such as an appliance (e.g., a beverage machine), after
its
manufacture and assembly. Often, the manufacture and assembly of the appliance
is
performed some distance from the ultimate shipping and distribution center.
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Consequently, the primary packaging 110 may be assembled, packaged with the
appliance, and sealed for distribution from the primary assembly location.
[0041] The illustrated secondary packaging 120 is configured to house adjunct
materials associated with the appliance. The adjunct materials may be
consumables
associated with an operation of the appliance. Possible consumables include
beverage
pods or other consumables that have a defined shelf-life, including various
teas, coffees,
alcohols, soups, carbonation cartridges, and variations and derivatives
thereof
[0042] The packaging system 100 may operate to allow for insertion of the
secondary
package 120 into an interior space of the primary package 110, without opening
a primary
access flap or other opening that is configured for the assembled appliance.
In this
regard, the adjunct materials of the secondary packaging 120 may be added to
the interior
space of the primary packaging 110 without disturbing the appliance or other
primary
contents of the primary packaging. The primary packaging 110 may therefore
maintain a
position, orientation, assemblage, and so on of the appliance or other primary
contents
within the interior space while the secondary packaging 120 is advanced into
the primary
packaging 110. The secondary packaging 120 is therefore inserted into the
primary
packaging 110 in an efficient and economical manner that may avoid repackaging
or
other rework associated with the appliance packaged in the primary package
110.
[0043] It will be appreciated that the primary and secondary packages
described herein
may be constructed in a variety of shapes, sizes, and from a variety of
different materials,
in order to accommodate the contents being packaged. In the example of FIG.
1A, the
primary packaging 110 is shown generally as a rectangular prism or cuboid
shape. The
primary packaging 110 includes walls 112. The walls 112 may be structural
walls that
define an interior space of the primary package 110. The walls 112 may have a
thickness
that provides structural support for the primary packaging 110 (and optionally
for the
secondary packaging 120), while also providing protection for primary contents
held
therein.
[0044] The primary packaging 110 also includes a primary access flap 114,
shown in
FIG. 1A. The primary access flap 114 is configured to provide access to an
interior space
of the primary package 110. For example, the primary access flap 114 may
include
hinged panels or other features that articulate over a primary opening defined
by the
primary packaging 110. Primary contents for packaging in the interior spaces
(e.g., an
appliance, including a beverage making machine) may generally be advanced into
the
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primary opening, for example, when the primary access flap 114 is in an open
configuration (such as that shown in FIG. 1A). The primary access flap 114 may
therefore have a size, shape, contour, and so forth that allow the primary
contents to be
advanced into the interior space, while also being able to cover the primary
opening, and
enclose the primary contents within the interior space.
[0045] The primary package 110 and secondary packaging 120 may be formed of
any
appropriate material used for packaging of appliances or other manufactured
and/or
associated articles. According to one exemplary embodiment, cardboard, a
polymer,
paper, cardstock, a laminate material, a composite based material, and the
like may be
used. In some cases, a corrugated material may be used to provide additional
structural
stiffness to the resulting packaging structures, or portions thereof
[0046] The packaging system 100 may generally include an opening feature to
allow
for the convenient and undisruptive insertion of secondary packaging, for
example,
subsequent to packaging and shipping primary contents, including an appliance.
In the
embodiment of FIG. 1A, an opening feature 130 is shown on one of the walls 112
that
define the interior space of the primary package 110. The opening feature 130
may
broadly be any appropriate structure or assembly or subassembly of components
that
allow for access into the interior space of the primary package 110, for
example, without
opening the primary access flap 114.
[0047] The opening feature 130 is shown in the example illustrated embodiments
as a
hinged door defined, in part, by perforations 131 formed through one or more
of the walls
112. It will be appreciated that the opening feature 130 may also include, or
be, various
other doors, seals, locks, sliding features, windows, screens, and so forth,
to facilitate the
functionality of the opening feature 130 described herein.
[0048] Broadly, the opening feature 130 provides the utility of inserting
adjunct and/or
essential materials at a location separate from the primary assembly location
without
requiring the opening of the primary (major or minor) flaps (e.g., primary
flap 114) of the
primary packaging 110. The adjunct and/or essential materials may be free or
may,
alternatively, be contained within the secondary packaging 120.
[0049] As described herein, the opening feature 130 may be a hinged door
formed by
one or more of the walls 112 of the primary package 110. For example, a
portion of the
walls 112 may include the perforations 131 that extend substantially through a
thickness
of the wall 112. The perforations 131 may extend along three distinct, and
connected
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lines, such as that shown in FIG. 1A. A portion of the walls 112 may be
separated from a
remainder of the wall 112 along the perforations 131, and thus be allowed to
articulate
along a non-perforated, or hinged edge.
[0050] According to one exemplary embodiment, the perforations 131 formed
through
the wall 112 of the primary packaging 110 are die-cut into the exterior wall
of the primary
package 110 prior to assembly. Alternatively, the perforations 131 may be
formed of any
number of manufacturing methods, including, but in no way limited to, laser
cutting,
punching, pressing, stamping, and so on. Furthermore, the perforations 131 may
be
formed through the wall 112 of the primary packaging 110 after the assembly of
the
primary package 112, such as in an assembly-line manufacturing process.
[0051] The opening feature 130 described herein may generally be re-closable
or re-
sealable. For example, the opening feature 130 is configured to articulate
over a
secondary opening, thereby allowing for insertion of the secondary packaging
120 into
the interior space of the primary packaging 110. Subsequent to insertion of
the secondary
packaging 120, the opening feature may further be articulated to cover the
secondary
opening, and enclose the secondary packaging 120 within the interior space of
the
primary packaging 110.
[0052] According to one embodiment, the adjunct or sample materials are housed
in
the secondary package 120. Alternatively, the adjunct or sample materials may
be
inserted into the primary packaging 110 via the opening feature 130 without
being housed
.. in the secondary packaging 120, wherein they will be loose articles within
the primary
packaging 110.
[0053] As illustrated, the secondary package 120 can be sized to securely pass
through
the opening feature 130, when it is opened. For example, as described in
greater detail
below, one or more internal features of the primary packaging 110, such as a
shelf, a
divider, an internal wall, and so forth, may define a compartment or other
feature that
retains the secondary packaging 120 within the interior space of the primary
packaging.
In some cases, this interior feature may help establish a friction fit with
the secondary
packaging 120, for example, in order to retain the secondary packaging
securely within
the interior space. Alternatively, the secondary packaging 120 or the loose
adjunct or
sample materials may be significantly smaller than the opening defined by the
perforated
door 130.
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[0054] As described above, FIG. 1A generally depicts the packaging system 100
in an
example open configuration. For example, in FIG. 1A, the primary access flaps
114 are
open and the secondary packaging 120 is removed from the interior space of the
primary
packaging 110.
[0055] With reference to FIG. 1B, the packaging system 100 is shown in a
configuration in which primary contents are enclosed in an interior space of
the primary
package 110. For example, FIG. 1B illustrates sample primary contents 102 held
within
an interior space 101 of the primary packaging 110. The primary contents 102
may be an
appliance, such as a beverage making machine, as described herein. In other
cases, the
primary contents 102 may be other assembled devices, appliances, apparatus,
and so forth
that may be manufactured remotely.
[0056] The primary contents 102 are shown in FIG. 1B generally supported
within the
interior space 102 by an internal feature 116. The internal feature 116 may be
an internal
shelf, wall, support, divider, and so on. The internal feature 116 and/or
other structure of
the primary packaging 110 may help maintain a position or orientation of the
primary
contents 102. The internal feature 116 may also help separate the primary
contents from
a portion or compartment of the primary packaging 110 that is configured to
receive the
secondary packaging 120. And as such, a position of the interior space of the
primary
packaging may be dedicated or reserved for the secondary packaging or loose
adjunct
materials. In part because the secondary packaging 120 may have its own
dedicated
portion of the internal space, the secondary packaging 120 may be inserted
into the
primary packaging without disturbing the position or orientation of the
primary contents
held therein. This functionality, allows the primary contents 102 to be
assembled and
package in final form (e.g., fully assembled, packaged) remotely, despite the
subsequent
addition of the secondary packaging 120.
[0057] With reference to FIG. 1C, the packaging system 100 is shown in a
configuration in which the secondary packaging 120 is received within the
primary
packaging 110. Figure 1C further illustrates sample adjunct materials 104 held
within the
secondary package 120. The adjunct materials 104 may be consumable materials
associated with the primary contents 102. As one possibility, the primary
content 102
may be an appliance, such as a beverage machine, and the adjunct materials 104
may be
beverage pods, cartridges, capsules, and/or other structures that are used to
facilitate one
or more operations of the beverage machine, such as brewing or otherwise
forming a
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beverage. The adjunct material 104 may have a short shelf life, such as a
period of
months, and thus it is advantageous to include the adjunct materials 104
within the
primary packaging 110 in relative proximity to a point of sale, rather than a
point of
manufacture.
[0058] As shown in FIG. 1C, the secondary packaging 120 is received within the
primary packaging 110 while the primary access flaps 114 remain closed. As
shown in
FIG. 1C, a position or orientation of the primary contents remain undisturbed
despite the
addition of the secondary packaging 120. As such, the secondary packaging 120
can be
added to the primary packaging 110 at a time substantially after the initial
assembly and
packaging of the primary contents 102, thereby helping maximize a possible
shelf live for
the adjunct materials inserted into the primary packaging 110 In this manner,
the primary
packaging 110 can maintain a position, orientation, assembled stated, and so
forth while
the secondary packaging 120 is inserted. Further, the secondary packaging 120
is
inserted into the primary packaging 110 while the primary access flap 114
and/or other
flap covering a primary opening remains closed.
[0059] FIG. 2 is a perspective view of the opening feature 130 formed in the
primary
packaging 110. In the example of FIG. 2, the opening feature 130 is a hinged
door,
shown in an open configuration. When in an open configuration, the opening
feature 130
is at least partially separated from a remainder of the wall of the primary
packaging 110.
The opening feature 130 can then articulate along a hinged edge 132 that is
not
perforated, and thus not separated from the primary packaging 110. The hinged
edge 132
may include a formed relief, a reduced amount of material, or another hinge
feature to
facilitate the hinging motion. Alternatively, the material used to form the
primary
packaging 110 may be sufficiently weak to create a bending site at the hinged
edge 132
when a bending force is exerted on the opening feature 130.
[0060] To facilitate separating the hinged door from the remainder of the wall
112 of
the primary packaging 110, a digit engagement feature 134 may be formed along
a free
edge. The digit engagement feature 134 includes a small cutout forming a
recess in the
hinged door. The digit engagement feature 134 allows for a user's finger to
engage the
door and provide sufficient force to break the connections between the
perforations,
allowing the door to bend and hinge upon its at least one connected edge
(e.g., hinged
edge 132), thereby allowing access to the internal portion of the primary
packaging 110.
While the digit engagement feature 134 is illustrated as a small cutout or
recess, any
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number of engagement features may be used, including, but in no way limited
to, a tab, a
mating feature, and the like.
[0061] According to one embodiment, the opening feature 130 is configured to
be a
hinged door re-closeable after the bending motion, allowing for the closure
and sealing,
for example, of the door. Closure of the opening feature 130 may be secured by
an
interference engagement between the edge of the opening feature 130 and the
mating
perforated edges of the primary packaging 110. Alternatively, another
engagement
feature can be formed to ensure closure. Furthermore, an adhesive or a sealing
member
may be used to securely close the opening feature 130 to the primary packaging
110 after
use.
[0062] As illustrated in FIG. 2, the primary package 110 may include an
internal
compartment 200. The internal compartment 200 may be configured to receive the
secondary packaging 120. For example, the internal compartment 200 may be
defined by
various internal shelves, walls, partitions, dividers, supports, and so on
that support the
secondary packaging 120, including constraining movement of the secondary
packaging
120 within the interior space of the primary packaging 110. In this manner,
the interior
space of the primary packaging 110 may have a dedicated, or even isolated,
portion
reserved for the secondary packaging 120; however, this is not required. As
described
herein, the secondary packing 120 (or adjunct materials more generally) may be
advanced
into the interior space loosely and/or without constraint inside of the
internal space of the
primary packaging 110.
[0063] According to one exemplary embodiment, the internal compartment 200 is
at
least partially defined by a plurality of internal compartment walls 220. As
shown, the
internal compartment walls 220 can form or define the internal compartment
200,
separating the adjunct or sample materials or the secondary packaging 120 from
the
appliance or other elements contained within the primary packaging 110. This
separation
can protect (e.g., define a protective barrier about) the adjunct or sample
materials or the
secondary packaging 120 during subsequent shipping, transport, or
distribution.
[0064] FIG. 2 also depicts other sample internal features that may facilitate
receiving
the secondary packaging 120 within the interior space of the primary packaging
110. For
example, FIG. 2 illustrates an internal feature 218 and an internal shelf 218.
In one
embodiment, the internal feature 218 may help separate the adjunct materials
from the
primary contents, such as an appliance, held within the primary packaging 110.
The
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internal feature 216 may therefore, along with other internal features or
walls of the
primary packaging, define a dedicated space for the adjunct materials within
the primary
packing 110. In turn, this may allow the primary packaging 110 to maintain a
position or
orientation of the primary contents (e.g., the primary contents may remain
substantially
undisturbed), notwithstanding the presence or absence of the secondary
packaging 120, or
associated adjunct materials.
[0065] The internal shelf 218, along with other internal features of the
primary
packaging 110 may also help receive and secure the secondary packaging 120
within the
interior space. For example, the internal shelf 218 may provide a platform or
internal
support, upon which the secondary packaging 120 may slide onto and rest within
the
primary packaging 110.
[0066] As described herein, the secondary packaging 120 may fit snuggly or
securely
within the primary packaging. In one embodiment, one or more of the internal
compartment walls 220, internal feature 216, internal shelf 218, and/or other
feature may
establish a friction fit with the secondary packaging 120. The friction fit
may operate to
restrain movement of the secondary packaging 120 within the primary packaging
110,
which may facilitate subsequent transport and sale activities.
[0067] According to one exemplary embodiment, the internal compartment walls
220,
internal feature 216, internal shelf 218, and so on are assembled and coupled
to the
internal surface of the primary packaging 110 during assembly of the primary
packaging
110. Coupling techniques include using any number of adhesives, fasteners, or
assembly
methods, including, but in no way limited to, glue, staples, and the like.
[0068] Additionally, as shown in FIG. 2, the primary packaging 110 may include
an
internal door 210. The internal door 210 may be formed from one or more walls
112 of
the primary packing. In some cases, the internal door 210 formed through an
interior
surface of the primary packaging 110 (e.g., using perforations) or as part of
the internal
compartment structural walls 220. As shown, the internal door 210 provides an
additional structural wall or surface defining the internal compartment 200.
[0069] When assembled, the internal door 210 can mate with the hinged
perforated
door 130. According to one exemplary embodiment, the internal door 210 is
formed as
part of an interior wall of the primary packaging 110 and processed to include
perforations similar to the hinged door defined by the opening feature 130.
Alternatively,
the internal door 210 can be a floating hinged flap that is not structurally
connected to
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either an internal layer of the primary packaging 110 or the internal
compartment walls
220. Moreover, similar to the hinged door of the opening feature, the internal
door 210
can include a hinged surface that may include a formed relief, a reduced
amount of
material, or another hinge feature to facilitate the hinging motion.
Alternatively, the
material used to form the internal door 210 may be sufficiently weak to create
a bending
site at the hinged edge when a bending force is exerted on the internal door
210.
[0070] FIG. 3 is a perspective view of the secondary packaging 120 inserted
into the
primary packaging 110 through the opening feature formed in the primary
packaging 110,
according to an embodiment. As illustrated, the wall 112 includes a secondary
opening
and the secondary packaging 120 passes through the secondary opening. The
opening
feature 130, internal door 210, and/or other feature of mechanism, may cover
the
secondary opening. In the configuration shown in FIG. 3, the opening feature
130 and
internal door 210 are articulated to a position that exposes the secondary
opening, and
allows for insertion of the secondary packaging 120 into the internal
compartment 200.
[0071] For example, the secondary packaging 120 may slide into the internal
compartment 200. Within the internal compartment 200, the secondary packaging
120
may rest or otherwise be supported by the internal shelf 218, the structural
walls 200, the
internal feature 216, and/or other structures of the primary packaging 110. In
the position
illustrated in the example of FIG. 3, the secondary packaging 120 may be
protected from
engagement with the appliance or other primary contents of the primary
packaging 110.
As shown, the secondary packaging 120 slides completely into the internal
compartment
200, and leaves sufficient space for the various engagement features, doors,
and so on to
enclose the secondary packaging 120 within the primary packaging 110.
[0072] FIG. 4 is a perspective assembled view of the secondary packaging 120
inserted
into the primary packaging 110, according to an embodiment. As illustrated,
the opening
feature 130 and the internal perforated door 210 are articulated to enclose
the secondary
packaging 120 within the primary packaging 120. In some cases, such as that
shown in
FIG. 4, the opening feature 130 may be flush with an outer surface of the
walls 112. In
this manner, the primary packaging 110 may maintain a consistent profile
around an outer
surface.
[0073] FIG. 5 is a perspective assembled view of a secondary packaging 120
inserted
into and sealed by a tamper-resistant sealer 500 within a primary packaging
110,
according to an embodiment. As shown, the tamper-resistant sealer 500 covers
the
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interface between the hinged perforated door 130 and the outer surface of the
primary
packaging 110. The tamper-resistant sealer 500 can be any adhesive or sealing
member
configured to seal the interface and secure the secondary packaging 120 within
the
internal compartment 200 including, but in no way limited to, glue, a sticker,
tape,
staples, and the like. According to one exemplary embodiment, the sealant
comprises
tamper-resistant tape that visibly demonstrates when it has been tampered with
by
physically and catastrophically tearing, mismatching patterns or letters,
changing color,
etc.
[0074] To facilitate the reader's understanding of the various functionalities
of the
embodiments discussed herein, reference is now made to the flow diagram in
FIG. 6,
.. which illustrates process 600. While specific steps (and orders of steps)
of the methods
presented herein have been illustrated and will be discussed, other methods
(including
more, fewer, or different steps than those illustrated) consistent with the
teachings
presented herein are also envisioned and encompassed with the present
disclosure.
[0075] In this regard, with reference to FIG. 6, process 600 relates generally
to
.. methods of assembling a package. The method 600 may be used with any of the
packages, packaging, packaging systems, and so on, described herein, for
example, such
as the packaging system or package 100, the primary packaging 110, the
secondary
packaging 120, and variations and embodiments thereof
[0076] At operation 604, packaging material may be laid out. The packaging
material
may be pre-cut into a desired pattern to form the primary packaging 110, or
the packaging
material may be customized to form the desired primary packaging. For example
and
with reference to FIG. 1A, corrugated material, or other packaging materials,
may be cut
in a pattern in order to form the walls 112.
[0077] At operation 608, access doors may be die cut. For example and with
reference
to FIG. 2, an opening feature 130, an internal door 210, or other feature may
be cut into
the walls 112. In some cases, this may involve forming the perforations 131
through a
thickness of the walls, and a user may subsequently separate a hinged door for
a
remainder of the wall. As noted above, the access doors may be cut by any
number of
manufacturing methods, including die-cutting, stamping, laser-cutting, and the
like.
Additionally, as mentioned above, the access doors may be formed after
assembly of the
primary packaging 110.
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100781 At operation 612, the primary packaging may be assembled, including
coupling
the outer walls of the primary packaging 110. For example and with reference
to FIG. 2,
internal walls 200, internal features 216, internal shelves 218, and so on may
be
connected to various surfaces within the primary packaging 110. Such features
may
define a dedicated space for the secondary packaging 120 within the primary
packaging
110, thereby allowing the secondary package 120 to be inserted into the
primary package
110 without disturbing primary contents held therein. According to one
embodiment, the
internal compartment 200 can be coupled to the primary packaging 110 during
assembly,
including the internal perforated door 210.
[0079] At operation 616, the appliance can then be packaged in the primary
packaging.
Subsequently, the primary packaging can then be shipped (with the primary
contents or
appliance) from the primary manufacturing assembly.
[0080] In this regard, a primary packaging may be provided so that at
operation 616,
primary contents may be packaged therein. For example, and with reference to
FIGs. 1A
and 2, a primary packaging 110 may be provided having a primary access flap
and an
opening feature. The opening feature allows for insertion of a secondary
packaging into
an interior defined by the primary packaging, while the primary access flaps
remain
closed.
[0081] Accordingly, operation 616 may involve packaging primary contents with
the
primary package. For example and with reference to FIG. 1B, primary contents
102 may
be packaged within the interior space 101 of the primary packaging 110. The
primary
contents 102 may be held within the interior space 101 of the primary
packaging 110, for
example, by an internal feature 116 and/or other elements, such as other
packaging
materials, foams, cushions, wrapping, fillers, and so on. When the primary
contents 102
are packaged within the primary package 110, the primary access flap 114 may
be closed,
thereby sealing the primary contents 102 within the primary packaging for
shipment or
other subsequent packaging processing.
[0082] At operation 620, the primary package may be received at a secondary
location.
At the secondary location, an interior of the primary packaging may be
accessed via
access doors. For example and with reference to FIG. 2, the opening feature
130 may be
articulated to uncover or reveal a secondary opening formed through a wall 112
of the
primary packaging.
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[0083] At operation 624, secondary items are inserted into the interior space
of the
primary packaging. This occurs without opening a primary access flap and/or
otherwise
disturbing primary contents of the primary packaging. For example and with
reference to
FIG. 3, the secondary packaging 120 (or loosely assembled) secondary packages,
samples, components and/or perishable items may be inserted into the interior
space of
the primary packaging 110, including in some embodiments, into the internal
compartment 200.
[0084] At operation 628, the secondary packaging and associated adjunct
materials
may be sealed within the primary packaging. For example and with reference to
FIG. 5, a
tamper-resistant tape, such as the sealer 500 may be adhered to and around an
area of the
wall 112 having the opening feature 130. In some cases, this may include an
adhered
label or overseal, which may help to deter pilferage/theft. The package may
then be
shipped to other distributors, points of sale, or consumers.
[0085] Other examples and implementations are within the scope and spirit of
the
disclosure and appended claims. For example, features implementing functions
may also
be physically located at various positions, including being distributed such
that portions
of functions are implemented at different physical locations. Also, as used
herein,
including in the claims, "or" as used in a list of items prefaced by "at least
one of"
indicates a disjunctive list such that, for example, a list of "at least one
of A, B, or C"
means A or B or C or AB or AC or BC or ABC (i.e., A and B and C). Further, the
term
"exemplary" does not mean that the described example is preferred or better
than other
examples.
[0086] The foregoing description, for purposes of explanation, uses specific
nomenclature to provide a thorough understanding of the described embodiments.
However, it will be apparent to one skilled in the art that the specific
details are not
required in order to practice the described embodiments. Thus, the foregoing
descriptions
of the specific embodiments described herein are presented for purposes of
illustration
and description. They are not targeted to be exhaustive or to limit the
embodiments to the
precise forms disclosed. It will be apparent to one of ordinary skill in the
art that many
modifications and variations are possible in view of the above teachings.
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